Soluble poly-4-methyl-1-pentene



' for the catalyst in a manner as yet unknown.

United States Patent 3,317,501 SOLUBLE POLY-4-METHYL-1-PENTENE William R. Edwards, Baytown, Tex., assignor, by mesne assignments, to Esso Research and Engineering Company, Elizabeth N.J., a corporation of Delaware No Drawing. Filed Oct. 16, 1963, Ser. No. 316,524 12 Claims. (Cl. 26093.7)

The present invention relates to a method of polymerizing 4-methyl-1-pentene. More particularly, the present invention relates to a method of polymerizing 4- methyl-l-pentene to obtain high molecular weight polymers while utilizing moderate temperatures of polymerization. In its most specific aspects, the present invention relates to a method of producing a poly-4-methyll-pentene having a molecular weight greater than 50,000 at reaction temperatures between '20 F. and +100 F.

Normally, in the polymerization of olefins, the desirable higher molecular weight polymers are obtained only at temperatures of 40 F. to 150 F. It is generally considered that the molecular weight of polymers increases as the temperature of polymerization is lowered. Since the higher molecular weights are desired for most commercial applications involving polymers, it has been the common practice to use temperatures as low as economically feasible. This increases the cost of production both from the standpoint of initial investment and operating costs in providing sufficient refrigeration to maintain these low temperatures.

Poly-4-methyl-1-pentene is an elastorneric polymer having uses similar to polyisobutylene. For example, it may be blended with polypropylene to get improved impact characteristics at low temperatures. Currently, temperatures of -40 F. to 150 F. are considered to be necessary in order to obtain high molecular weight po1y-4-methyl-1-pentene; that is, molecular weights in the range of 75,000 to 100,000 as a minimum.

It has been found that high molecular weight poly-4- methyl-l-pentene can be produced at temperatures of -20 F. to +100 F. by using the proper catalyst solvent system, thus allowing the polymerization reaction to be accomplished at the boiling point of the solvent system which is used. This expedient allows the use of autorefrigeration as a means for controlling the temperature of the highly exothermic reaction, and minimizes the refrigeration facilities which must be provided for the polymerization unit.

By the practice of the present invention, it has been found that high molecular weight poly-4-methyl-lpentene can be produced at the higher temperatures by using solid aluminum chloride as a catalyst, with a suitable deactivator. Pure methyl chloride is a preferred solvent, but suitable solvents are paraflins which do not contain a tertiary carbon atom, such as the group consisting of neopentane, n-pentane, n-hexane, etc., all of which must be combined with at least 4% (preferably 20%) methyl halide such as methyl chloride. Pure methyl halide is preferred as the solvent in these systems, with methyl chloride being the specific halide which is preferred. The methyl halide acts as an activator It is thought that a halide transfer between the methyl halide and the catalyst may be the operative factor.

It has been found, however, that when using solid aluminum chloride in combination with a methyl halidecontaining catalyst for the polymeriration of 4-methyl-1- pentene, at the higher temperature the 4-methyl-1-pentene polymer tends to become cross-linked and therefore insoluble in hydrocarbons. Where a soluble polymer product is preferred, for example where solution casting is to be used, the tendency to produce the insoluble (cross-linked) poly-4-methyl-1-pentene is controlled by adding deactivators to the solvent system. These deactivators shift the polymer reaction in the direction of forming a soluble polymer, even though some insoluble polymer may also be formed in the reaction.

Tertiary carbon-containing parafiins have been found to be reactive in the present process to such an extent that they may be used as deactivators to favor the formation of soluble polymer at the expense of insoluble polymer. Whereas compounds such as isobutane and isopentane have heretofore been thought to be nonreactive under such conditions as those employed in the present process, it has been found to the contrary that even small amounts of these tertiary carbon-containing parafiins react in the system to a sufficient extent that the formation of soluble polymer is enhanced at the expense of the formation of insoluble polymer, and employment of large quantities of the deactivator results in a radical lessening in the molecular weight of the polymer formed. Other suitable deactivators are found in the diolefins such as isoprene, 1,3-butadiene, and 1,4-pentadiene, monoolefins such as butene-l, pentene-l, etc., and higher alkyl chlorides such as ethyl chloride, propyl chloride, etc. As a generalization, it may be stated that compounds which easily form carbonium ions can be used as deactivators if employed in small amounts. Isobutylene is exemplary of such a carbonium ion-forming compound.

In order to establish the operability of the various catlysts set forth, the following runs were made.

Example I To 50 cc. of refluxing methyl chloride at atmospheric pressure was added 0.50 g. of solid aluminum chloride powder. Immediately thereafter were added 10 cc. of 4-methyl-l-pentene. A vigorous polymerization occurred instantaneously, yielding poly-4-methyl-1-pentene based on monomer charged. The polymer was exclusively insoluble in hydrocarbon. No soluble polymer was formed. The temperature of the reaction was 10 F.

Example II The procedure of Example I was followed with the exception that the methyl chloride contained 1% isoprene. A soluble solid 4-rnethyl-1-pentene having a molecular weight of about 75,000 was obtained. No insoluble polymer was formed.

Example III To a refluxing mixture of 50 cc. of methyl chloride and 20 cc. of 4-methyl-1-pentene was added 0.5 cc. of a 15 weight percent solution of monoethyl aluminum dichloride in n-heptane. A moderately fast reaction was observed which gave a polymer yield of 30%, based on monomer charged. About 40% of the polymer product was insoluble in hydrocarbons, but the soluble polymer product had a molecular weight within the range of 200,000 to 250,000. The temperature of the reaction was about -10 F.

Example IV The procedure of Example HI was followed using various amounts of diethyl aluminum chloride. No reaction was obtained in the case. Thus, diethyl aluminum chloride is established not to be effective as a catalyst in this reaction.

By a comparison of Examples I through 1V, it is seen that the use of solid aluminum chloride in connection with methyl chloride solvent produced an exclusively insoluble poly-4-methyl-1-pentene. When isoprene was used as the deactivator, the solid aluminum chloride catalyst produced a soluble poly-4-methyl-1-pentene having a molecular weight of 75,000. Thus, it is seen that aluminum chloride may be used as a solid if a suitable deactivator is soluble polymer product having a molecular weight of employed. only 10,000. Likewise, the isobutylene appears to have Thus, it is shown by Examples I to IV that the polyma similarly high activity in reducing the molecular weight erization of 4-methyl-1-pentene may be carried out at of the product. The amount of the tertiary carbon-contemperatures of -10 F. or greater while using solid 5 taining compound can be easily determined, however, by aluminum chloride as a catalyst, with a suitable deacroutine experimentation by those skilled in the art. tivator. Thus, it is submitted that the present invention pro- In order to establish the suitability of various solvents vides a method of polymerizing 4-methyl-1-pentene at for use in the process of the present invention, a number higher temperatures than those hetertofore thought posof runs were made while utilizing solid aluminum chlol0 sible, without suffering a deleterious loss in molecular ride as a catalyst. In general, the procedure of Example weight of the final product. Further, by the practice of I was utilized The results of these runs are set forth the present invention, the polymer product may be probelow in Table I. duced in a soluble form suitable for solution casting.

TABLE I.EVALUATION 0F SOLVENIS Example Catalyst Solvent Tempera- Polymer Molecular Remarks turc, F. Weight Solid A101 Methyl chloride Insoluble No soluble polymer obtained. V do Methyl bromide Do. VI do Methyl chloride, 80% 0 100,000 All polymer was soluble.

neopentane. VII .do 4% Methyl chloride, 96% nco- 50 d0 75,000+ Do. pentane. d Neopentane 50 Soluble semi-solid- 10, 000 Drasticloss in molecular weight.

50% Methyl chloride, 50% n- 10 48% Soluble solid 150,000 Shifts toward soluble, high molecular Weight polymer. 100 Soluble semi-sohd..- 10, 000 Drasgic loss in molecular weight.

54 Viscous oil 117 5,000 Do. 170 do 5,000 Do. 115 Soluble semi-solid..- 10,000 Do.

Thus, it is seen that a wide range of solvents can be Having disclosed in detail the essence of the present used. In the case of methyl chloride and solid aluminum invention, what is desired to be covered by Letters Patent chloride, it is noted that the use of a diluent such as should be limited only by the appended claims and not neopentane and n-pentane which dilutes the methyl chloby the specific examples herein given.

ride shifts the reaction from the formation of insoluble I claim:

polymer in the direction of forming the soluble polymer. 3: 1. A method of polymerizing 4-methyl-1-pentene which However, the use of these diluents alone (without a comprises methyl halide) results in the formation of very low contacting 4 methyl l pentene at g to R molecular weight products. Thus, it is established that with a Solid aluminum chloride catalyst the PresenCe of a methyl halide is essential in the withasolvent containing at least 4% by weight methyl reaction. 40 halide,

Note that Examples XI, XII, and XIII illustrate that and an eiiective amount of a catalyst deactivator chosen alkyl halides other than methyl halides are deactivators from the group consisting of alkyl chlorides containin the claimed system. ing at least two carbon atoms, diolefins, and tertiary In order to establish the use of tertiary carbon-concarbon-containing compounds other than 4-met'hyltaining deactivators for the solid aluminum chloride, l-pentene. another series of experimental runs were made. In these 2. A method in accordance with claim 1 wherein the runs, the procedure of Example II was used and various methyl halide is methyl chloride. tertiary carbon-containing compounds were included in 3. A method in accordance with claim 1 wherein the the methyl chloride solvent. methyl halide is methyl bromide.

TABLE IL-EVALUATION OF DEAC'IIVATORS FOR SOLID AlCls Molecular Example Methyl Chloride Containing Ratio of t-earbon compound Pr d t Weight of 4-methyl-1-pentene Soluble Polymer XV Isopentane (1%) 0 03 45% Soluble. 150,000 XVL Isobutane (1%)--. 03 20% Soluble 150,000 XVII Isobutane (2 U 100% Soluble 10, 000 XVIII. Isobutylene (5%) do 10, 000 XIX 3-methyl-1-butene (5%) 0.17 Soluble"..- 75, 000 XX 3-metl1yl-1-butene (13%). 1- 0 100% Soluble 50, 000 XXI 3methyl-1-penteue (20%). 1- Solub1e. 50,000

F m Table then, it is Obvious that the tertiary 4. A method in accordance with claim 1 wherein said carbon-containing compound which 15 to be used in con- Solvent contains at least 20% h l h 1id trolling the insolubility of the product is to be used in 5 A method in accordance with claim 4 wherein the extremely small quantities or the molecular weight of methyl halide is methy1ch10ride the final product is severely reduced. However, the amount of tertiary carbon-containing compound to be 7 I used depends not only on the particular molecular weight 3 2 12 2: .methyl g i l 1 h th which is desired, but also the nature of the tertiary car- 70 me m accor ance W1 6 am W erem e ban-containing compound itself. Thus, it is seen that the solvent is methyl chloride- 6. A method in accordance with claim 4 wherein the use f (H7 mol of 1 1 mol of 8. A method in accordance with claim 1 wherein the methyl-l-pentene produces 55% soluble product having Solvent is 100% methyl f a molecular weight of 75,000, whereas the use of approxi- 9- A method of polymerizing 4-methyl-l-pentene mately the same amount of isobutane produces a 100% 7 which comprises contacting 4-methyl-1-pentene at a temperature of of about -l0 F.

with a solid aluminum chloride catalyst and with a refluxing methyl chloride solvent,

said methyl chloride solvent containing 1% isoprene as a catalyst deactivator,

whereby a hydrocarbon-soluble poly-4-methyl-l-pentene is obtained.

10. A method of polymerizing 4-rnethyl-1-pentene which comprises which comprises contacting 4-met-hyl-1-pentene at a temperature of about -10 F.

contacting 4-methyl-1-pentene at a temperature of 10 wi h a solid aluminum chloride catalyst and about 10 F. with a refluxing methyl chloride solvent, with a solid aluminum chloride catalyst and said methyl chloride containing about 5% 3-methylwith a refluxing methyl chloride solvent, l-blltene as deactivat'or, said methyl chloride solvent containing 1% isopentane 15 whereby a hydrocarbon-Soluble P Y- Y -P as a deactivator,

whereby a hydrocarbon-soluble tene is obtained.

11. A method of polymerizing 4-methyl-1-pentene poly-4-methyl-1-pentene product is obtained.

No references cited.

20 JOSEPH L. SCHOFER, Primary Examiner.

which comprises contacting 4-methyl-1-pentene at a temperature of about 10 F.

JAMES A. SEIDLECK, Examiner. M. B. KURTZMAN, Assistant Examiner. 

1. A METHOD OF POLYMERIZING 4-METHYL-1-PENTENE WHICH COMPRISES CONTACTING 4-METHYL-1-PENTENE AT -20*F. TO +100*F. WITH A SOLID ALUMINUM CHLORIDE CATALAYST, WITH A SOLVENT CONTAINING AT LEAST 4% BY WEIGHT METHYL HALIDE, AND AN EFFECTIVE AMOUNT OF A CATALYST DEACTIVATOR CHOSEN FROM THE GROUP CONSISTING OF ALKYL CHLORIES CONTAINING AT LEAST TWO CARBON ATOMS, DIOLEFINS, AND TERTIARY CARBON-CONTAINING COMPOUNDS OTHER THAN 4-METHYL1-PENTENE. 